SE545698C2 - A method for manufacturing a barrier layer for a paper or paperboard based packaging laminate - Google Patents
A method for manufacturing a barrier layer for a paper or paperboard based packaging laminateInfo
- Publication number
- SE545698C2 SE545698C2 SE2250283A SE2250283A SE545698C2 SE 545698 C2 SE545698 C2 SE 545698C2 SE 2250283 A SE2250283 A SE 2250283A SE 2250283 A SE2250283 A SE 2250283A SE 545698 C2 SE545698 C2 SE 545698C2
- Authority
- SE
- Sweden
- Prior art keywords
- layer
- substrate
- barrier
- paper
- vacuum coating
- Prior art date
Links
- 230000004888 barrier function Effects 0.000 title claims abstract description 185
- 239000011087 paperboard Substances 0.000 title claims abstract description 108
- 239000000123 paper Substances 0.000 title claims abstract description 103
- 238000000034 method Methods 0.000 title claims abstract description 64
- 238000004806 packaging method and process Methods 0.000 title claims abstract description 51
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 10
- 239000010410 layer Substances 0.000 claims abstract description 206
- 239000000758 substrate Substances 0.000 claims abstract description 203
- 239000011247 coating layer Substances 0.000 claims abstract description 133
- 238000001771 vacuum deposition Methods 0.000 claims abstract description 128
- 238000000576 coating method Methods 0.000 claims abstract description 102
- 239000011248 coating agent Substances 0.000 claims abstract description 68
- 239000012790 adhesive layer Substances 0.000 claims abstract description 50
- 229920002678 cellulose Polymers 0.000 claims abstract description 38
- 239000001913 cellulose Substances 0.000 claims abstract description 38
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 30
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 23
- 229910052782 aluminium Inorganic materials 0.000 claims description 19
- 239000000463 material Substances 0.000 claims description 18
- KRKNYBCHXYNGOX-UHFFFAOYSA-N citric acid Chemical compound OC(=O)CC(O)(C(O)=O)CC(O)=O KRKNYBCHXYNGOX-UHFFFAOYSA-N 0.000 claims description 13
- 238000001035 drying Methods 0.000 claims description 13
- 239000006185 dispersion Substances 0.000 claims description 12
- 239000004372 Polyvinyl alcohol Substances 0.000 claims description 11
- 229920002451 polyvinyl alcohol Polymers 0.000 claims description 11
- 235000019422 polyvinyl alcohol Nutrition 0.000 claims description 11
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 10
- 230000005540 biological transmission Effects 0.000 claims description 10
- 239000001301 oxygen Substances 0.000 claims description 10
- 229910052760 oxygen Inorganic materials 0.000 claims description 10
- 239000000203 mixture Substances 0.000 claims description 9
- 239000002985 plastic film Substances 0.000 claims description 9
- 229920006255 plastic film Polymers 0.000 claims description 9
- 239000002998 adhesive polymer Substances 0.000 claims description 7
- 229920003169 water-soluble polymer Polymers 0.000 claims description 7
- 238000004132 cross linking Methods 0.000 claims description 5
- 238000010030 laminating Methods 0.000 claims description 4
- 229920000896 Ethulose Polymers 0.000 claims description 3
- 239000001859 Ethyl hydroxyethyl cellulose Substances 0.000 claims description 3
- 229920002488 Hemicellulose Polymers 0.000 claims description 3
- 235000019326 ethyl hydroxyethyl cellulose Nutrition 0.000 claims description 3
- 230000005855 radiation Effects 0.000 claims description 3
- 229920000663 Hydroxyethyl cellulose Polymers 0.000 claims description 2
- 239000004354 Hydroxyethyl cellulose Substances 0.000 claims description 2
- 229920002153 Hydroxypropyl cellulose Polymers 0.000 claims description 2
- 229920001046 Nanocellulose Polymers 0.000 claims description 2
- DPXJVFZANSGRMM-UHFFFAOYSA-N acetic acid;2,3,4,5,6-pentahydroxyhexanal;sodium Chemical compound [Na].CC(O)=O.OCC(O)C(O)C(O)C(O)C=O DPXJVFZANSGRMM-UHFFFAOYSA-N 0.000 claims description 2
- 239000001768 carboxy methyl cellulose Substances 0.000 claims description 2
- 229920002301 cellulose acetate Polymers 0.000 claims description 2
- 235000019447 hydroxyethyl cellulose Nutrition 0.000 claims description 2
- 239000001863 hydroxypropyl cellulose Substances 0.000 claims description 2
- 235000010977 hydroxypropyl cellulose Nutrition 0.000 claims description 2
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims description 2
- 235000019812 sodium carboxymethyl cellulose Nutrition 0.000 claims description 2
- 229920001027 sodium carboxymethylcellulose Polymers 0.000 claims description 2
- 150000007524 organic acids Chemical class 0.000 claims 2
- 229920000642 polymer Polymers 0.000 description 35
- -1 polyethylene Polymers 0.000 description 18
- 239000011888 foil Substances 0.000 description 16
- 239000007788 liquid Substances 0.000 description 16
- 239000004698 Polyethylene Substances 0.000 description 15
- 229920000573 polyethylene Polymers 0.000 description 15
- 229910052500 inorganic mineral Inorganic materials 0.000 description 13
- 239000011707 mineral Substances 0.000 description 13
- 239000000853 adhesive Substances 0.000 description 11
- 230000001070 adhesive effect Effects 0.000 description 11
- 239000000835 fiber Substances 0.000 description 10
- 229920000098 polyolefin Polymers 0.000 description 10
- 239000000243 solution Substances 0.000 description 10
- 229920003043 Cellulose fiber Polymers 0.000 description 9
- 230000008569 process Effects 0.000 description 9
- 239000011230 binding agent Substances 0.000 description 8
- 235000013305 food Nutrition 0.000 description 8
- 238000007765 extrusion coating Methods 0.000 description 7
- 239000005022 packaging material Substances 0.000 description 7
- 238000005240 physical vapour deposition Methods 0.000 description 7
- 239000007787 solid Substances 0.000 description 7
- 229920001131 Pulp (paper) Polymers 0.000 description 6
- 239000006260 foam Substances 0.000 description 6
- 239000004816 latex Substances 0.000 description 6
- 229920000126 latex Polymers 0.000 description 6
- 229920003023 plastic Polymers 0.000 description 6
- 239000004033 plastic Substances 0.000 description 6
- 229920000139 polyethylene terephthalate Polymers 0.000 description 6
- 239000005020 polyethylene terephthalate Substances 0.000 description 6
- 239000000126 substance Substances 0.000 description 6
- 229910017107 AlOx Inorganic materials 0.000 description 5
- 239000004743 Polypropylene Substances 0.000 description 5
- 238000005229 chemical vapour deposition Methods 0.000 description 5
- 239000003431 cross linking reagent Substances 0.000 description 5
- 239000007789 gas Substances 0.000 description 5
- 238000003475 lamination Methods 0.000 description 5
- 229920001155 polypropylene Polymers 0.000 description 5
- 239000011253 protective coating Substances 0.000 description 5
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 4
- 238000005336 cracking Methods 0.000 description 4
- 229910052751 metal Inorganic materials 0.000 description 4
- 239000002184 metal Substances 0.000 description 4
- 238000001465 metallisation Methods 0.000 description 4
- 239000003960 organic solvent Substances 0.000 description 4
- 239000011241 protective layer Substances 0.000 description 4
- 239000005995 Aluminium silicate Substances 0.000 description 3
- 229920002472 Starch Polymers 0.000 description 3
- 235000012211 aluminium silicate Nutrition 0.000 description 3
- 230000008901 benefit Effects 0.000 description 3
- 229920001903 high density polyethylene Polymers 0.000 description 3
- 239000004700 high-density polyethylene Substances 0.000 description 3
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 3
- 229920001684 low density polyethylene Polymers 0.000 description 3
- 239000004702 low-density polyethylene Substances 0.000 description 3
- 230000003287 optical effect Effects 0.000 description 3
- 230000001681 protective effect Effects 0.000 description 3
- 238000004064 recycling Methods 0.000 description 3
- 238000007670 refining Methods 0.000 description 3
- 239000008107 starch Substances 0.000 description 3
- 235000019698 starch Nutrition 0.000 description 3
- 239000003232 water-soluble binding agent Substances 0.000 description 3
- 229920002799 BoPET Polymers 0.000 description 2
- 229920000954 Polyglycolide Polymers 0.000 description 2
- 229920001328 Polyvinylidene chloride Polymers 0.000 description 2
- XECAHXYUAAWDEL-UHFFFAOYSA-N acrylonitrile butadiene styrene Chemical compound C=CC=C.C=CC#N.C=CC1=CC=CC=C1 XECAHXYUAAWDEL-UHFFFAOYSA-N 0.000 description 2
- 239000007864 aqueous solution Substances 0.000 description 2
- 239000003125 aqueous solvent Substances 0.000 description 2
- 235000019568 aromas Nutrition 0.000 description 2
- 229910000019 calcium carbonate Inorganic materials 0.000 description 2
- 125000002057 carboxymethyl group Chemical group [H]OC(=O)C([H])([H])[*] 0.000 description 2
- 238000007872 degassing Methods 0.000 description 2
- 238000000151 deposition Methods 0.000 description 2
- 239000004088 foaming agent Substances 0.000 description 2
- 238000007756 gravure coating Methods 0.000 description 2
- 239000011121 hardwood Substances 0.000 description 2
- 239000002655 kraft paper Substances 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 235000019645 odor Nutrition 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- 230000000704 physical effect Effects 0.000 description 2
- 239000005014 poly(hydroxyalkanoate) Substances 0.000 description 2
- 239000004633 polyglycolic acid Substances 0.000 description 2
- 229920000903 polyhydroxyalkanoate Polymers 0.000 description 2
- 229920006254 polymer film Polymers 0.000 description 2
- 229920002635 polyurethane Polymers 0.000 description 2
- 239000004814 polyurethane Substances 0.000 description 2
- 229920002689 polyvinyl acetate Polymers 0.000 description 2
- 239000011118 polyvinyl acetate Substances 0.000 description 2
- 239000002987 primer (paints) Substances 0.000 description 2
- 238000004537 pulping Methods 0.000 description 2
- 239000000725 suspension Substances 0.000 description 2
- 229920001169 thermoplastic Polymers 0.000 description 2
- 238000011282 treatment Methods 0.000 description 2
- 238000009489 vacuum treatment Methods 0.000 description 2
- 229920002554 vinyl polymer Polymers 0.000 description 2
- 239000002023 wood Substances 0.000 description 2
- NJVOHKFLBKQLIZ-UHFFFAOYSA-N (2-ethenylphenyl) prop-2-enoate Chemical compound C=CC(=O)OC1=CC=CC=C1C=C NJVOHKFLBKQLIZ-UHFFFAOYSA-N 0.000 description 1
- 241000609240 Ambelania acida Species 0.000 description 1
- NOWKCMXCCJGMRR-UHFFFAOYSA-N Aziridine Chemical compound C1CN1 NOWKCMXCCJGMRR-UHFFFAOYSA-N 0.000 description 1
- 235000017166 Bambusa arundinacea Nutrition 0.000 description 1
- 235000017491 Bambusa tulda Nutrition 0.000 description 1
- 241001330002 Bambuseae Species 0.000 description 1
- 241001474374 Blennius Species 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 229920002134 Carboxymethyl cellulose Polymers 0.000 description 1
- 102100024133 Coiled-coil domain-containing protein 50 Human genes 0.000 description 1
- 102000004190 Enzymes Human genes 0.000 description 1
- 108090000790 Enzymes Proteins 0.000 description 1
- 101000910772 Homo sapiens Coiled-coil domain-containing protein 50 Proteins 0.000 description 1
- 239000004368 Modified starch Substances 0.000 description 1
- 229920000881 Modified starch Polymers 0.000 description 1
- 235000015334 Phyllostachys viridis Nutrition 0.000 description 1
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 1
- 239000002174 Styrene-butadiene Substances 0.000 description 1
- 241000209140 Triticum Species 0.000 description 1
- 235000021307 Triticum Nutrition 0.000 description 1
- 229920002433 Vinyl chloride-vinyl acetate copolymer Polymers 0.000 description 1
- 229920002522 Wood fibre Polymers 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 239000002313 adhesive film Substances 0.000 description 1
- 150000001299 aldehydes Chemical class 0.000 description 1
- 150000001408 amides Chemical class 0.000 description 1
- 239000007900 aqueous suspension Substances 0.000 description 1
- 238000009455 aseptic packaging Methods 0.000 description 1
- 239000010905 bagasse Substances 0.000 description 1
- 239000011425 bamboo Substances 0.000 description 1
- 238000010009 beating Methods 0.000 description 1
- 239000000440 bentonite Substances 0.000 description 1
- 229910000278 bentonite Inorganic materials 0.000 description 1
- SVPXDRXYRYOSEX-UHFFFAOYSA-N bentoquatam Chemical compound O.O=[Si]=O.O=[Al]O[Al]=O SVPXDRXYRYOSEX-UHFFFAOYSA-N 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- MTAZNLWOLGHBHU-UHFFFAOYSA-N butadiene-styrene rubber Chemical compound C=CC=C.C=CC1=CC=CC=C1 MTAZNLWOLGHBHU-UHFFFAOYSA-N 0.000 description 1
- 238000003490 calendering Methods 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 125000003178 carboxy group Chemical group [H]OC(*)=O 0.000 description 1
- 235000010948 carboxy methyl cellulose Nutrition 0.000 description 1
- 239000011111 cardboard Substances 0.000 description 1
- 206010061592 cardiac fibrillation Diseases 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 125000002091 cationic group Chemical group 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 229920001577 copolymer Polymers 0.000 description 1
- 238000007766 curtain coating Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000009820 dry lamination Methods 0.000 description 1
- 239000000839 emulsion Substances 0.000 description 1
- 239000003000 extruded plastic Substances 0.000 description 1
- 230000002600 fibrillogenic effect Effects 0.000 description 1
- 239000007888 film coating Substances 0.000 description 1
- 238000009501 film coating Methods 0.000 description 1
- 235000011389 fruit/vegetable juice Nutrition 0.000 description 1
- 125000000524 functional group Chemical group 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000012793 heat-sealing layer Substances 0.000 description 1
- 230000007062 hydrolysis Effects 0.000 description 1
- 238000006460 hydrolysis reaction Methods 0.000 description 1
- 229920005610 lignin Polymers 0.000 description 1
- 239000007791 liquid phase Substances 0.000 description 1
- 230000001404 mediated effect Effects 0.000 description 1
- 239000012528 membrane Substances 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- GDOPTJXRTPNYNR-UHFFFAOYSA-N methyl-cyclopentane Natural products CC1CCCC1 GDOPTJXRTPNYNR-UHFFFAOYSA-N 0.000 description 1
- 230000000813 microbial effect Effects 0.000 description 1
- 230000005012 migration Effects 0.000 description 1
- 238000013508 migration Methods 0.000 description 1
- 235000013336 milk Nutrition 0.000 description 1
- 239000008267 milk Substances 0.000 description 1
- 210000004080 milk Anatomy 0.000 description 1
- 239000002480 mineral oil Substances 0.000 description 1
- 235000010446 mineral oil Nutrition 0.000 description 1
- 235000019426 modified starch Nutrition 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 229920002401 polyacrylamide Polymers 0.000 description 1
- 239000004626 polylactic acid Substances 0.000 description 1
- 229920000036 polyvinylpyrrolidone Polymers 0.000 description 1
- 239000001267 polyvinylpyrrolidone Substances 0.000 description 1
- 235000013855 polyvinylpyrrolidone Nutrition 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000002203 pretreatment Methods 0.000 description 1
- 239000013615 primer Substances 0.000 description 1
- 238000007639 printing Methods 0.000 description 1
- 102000004169 proteins and genes Human genes 0.000 description 1
- 108090000623 proteins and genes Proteins 0.000 description 1
- 125000001453 quaternary ammonium group Chemical group 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 229910052814 silicon oxide Inorganic materials 0.000 description 1
- 239000011122 softwood Substances 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 239000010902 straw Substances 0.000 description 1
- 239000011115 styrene butadiene Substances 0.000 description 1
- 229920003048 styrene butadiene rubber Polymers 0.000 description 1
- 239000000454 talc Substances 0.000 description 1
- 229910052623 talc Inorganic materials 0.000 description 1
- 239000002966 varnish Substances 0.000 description 1
- 238000009736 wetting Methods 0.000 description 1
- 239000002025 wood fiber Substances 0.000 description 1
Classifications
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H19/00—Coated paper; Coating material
- D21H19/02—Metal coatings
- D21H19/08—Metal coatings applied as vapour, e.g. in vacuum
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/10—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B29/00—Layered products comprising a layer of paper or cardboard
- B32B29/02—Layered products comprising a layer of paper or cardboard next to a fibrous or filamentary layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/02—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
- B32B37/025—Transfer laminating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J7/00—Chemical treatment or coating of shaped articles made of macromolecular substances
- C08J7/04—Coating
- C08J7/048—Forming gas barrier coatings
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/0005—Separation of the coating from the substrate
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/02—Pretreatment of the material to be coated
- C23C14/024—Deposition of sublayers, e.g. to promote adhesion of the coating
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/06—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
- C23C14/08—Oxides
- C23C14/081—Oxides of aluminium, magnesium or beryllium
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H11/00—Pulp or paper, comprising cellulose or lignocellulose fibres of natural origin only
- D21H11/16—Pulp or paper, comprising cellulose or lignocellulose fibres of natural origin only modified by a particular after-treatment
- D21H11/18—Highly hydrated, swollen or fibrillatable fibres
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H19/00—Coated paper; Coating material
- D21H19/10—Coatings without pigments
- D21H19/14—Coatings without pigments applied in a form other than the aqueous solution defined in group D21H19/12
- D21H19/34—Coatings without pigments applied in a form other than the aqueous solution defined in group D21H19/12 comprising cellulose or derivatives thereof
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
- D21H27/10—Packing paper
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2255/00—Coating on the layer surface
- B32B2255/02—Coating on the layer surface on fibrous or filamentary layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2255/00—Coating on the layer surface
- B32B2255/12—Coating on the layer surface on paper layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2255/00—Coating on the layer surface
- B32B2255/20—Inorganic coating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B82Y30/00—Nanotechnology for materials or surface science, e.g. nanocomposites
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/06—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
- C23C14/14—Metallic material, boron or silicon
- C23C14/20—Metallic material, boron or silicon on organic substrates
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
- C23C14/228—Gas flow assisted PVD deposition
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
- C23C14/56—Apparatus specially adapted for continuous coating; Arrangements for maintaining the vacuum, e.g. vacuum locks
- C23C14/562—Apparatus specially adapted for continuous coating; Arrangements for maintaining the vacuum, e.g. vacuum locks for coating elongated substrates
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- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H21/00—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties
- D21H21/50—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties characterised by form
- D21H21/52—Additives of definite length or shape
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- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Polymers & Plastics (AREA)
- Medicinal Chemistry (AREA)
- Health & Medical Sciences (AREA)
- Laminated Bodies (AREA)
- Making Paper Articles (AREA)
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Abstract
The present invention relates to a method for manufacturing a barrier layer for a paper or paperboard based packaging laminate, said method comprising: a) providing a barrier substrate comprising at least 50 wt% highly refined cellulose pulp (HRC) based on dry weight of the barrier substrate, said HRC having a Schopper-Riegler (SR) number above 80 as determined by standard ISO 5267-1, b) providing a transfer coating substrate comprising a vacuum coating layer and a backing layer separated by a release layer, and c) transferring the vacuum coating layer from the backing layer to the barrier substrate by a transfer coating process using an adhesive layer applied on the barrier substrate and/or the vacuum coating layer to obtain a barrier layer for a paper or paperboard based packaging laminate.
Description
A METHOD FOR MANUFACTURING A BARRIER LAYER FOR A PAPER OR PAPERBOARD BASED PACKAGING LAMINATE
Technical field
The present disclosure relates to barrier layers for paper or paperboard based
packaging materials. More specifically, the present disclosure relates to barrier layers for paper or paperboard based packaging Iaminates having low oxygen
transmission rate (OTR) and low water vapor transmission rate (WVTR).
Background Coating of paper and paperboard with plastics is often employed to combine the
mechanical properties of the paper or paperboard with the barrier and sealing properties of a plastic film. Paper or paperboard provided with even a relatively small amount of a suitable plastic material can provide the properties needed to make the paper or paperboard suitable for many demanding applications, for example as liquid or food packaging board. ln liquid or food packaging board, polyolefin coatings are frequently used as liquid barrier layers, heat sealing layers and adhesives. However, the recycling of such polymer coated board is difficult since it is difficult to separate the polymers from the fibers.
Also, in many cases the water vapor barrier properties of the polymer coated paper or paperboard are still insufficient unless the coating layers are thick or combinations of different polymer coating layers are used. Therefore, in order to ensure high water vapor barrier properties, the polymer coated paper or paperboard is often combined with one or more layers of aluminum foil. However, the addition of polymer and aluminum foil add significant costs and the combination of polymer coating layers and aluminum foils makes recycling of the materials more difficult. Also, due to its high carbon footprint there is a wish to
replace aluminum foils in paper and paperboard based packaging materials.
Aseptic packaging for long shelf-life products such as milk and juices are usually made from liquid or food packaging board comprising a multilayer paperboard
based substrate, an outermost heat-sealable polyolefin (e.g. polyethylene, PE)layer and innermost layers of polyolefin and aluminum. The aluminum foil layer, needed to provide water vapor and oxygen barrier properties, is usually incorporated between layers of polyethylene to provide the following structure: PE/paperboard/PE/ aluminum/PE.
ln the prior art, attempts have been made to replace the aluminum foil with more environmentally friendly and/or easier to recycle solutions, but so far with no real success. For example, microfibrillated cellulose (MFC) films and coatings have been developed, in which defibrillated cellulosic fibrils have been dispersed e.g. in water and thereafter re-organized and rebonded together to form a dense film or coating with excellent gas barrier properties. Unfortunately, the water vapor and gas barrier properties of such MFC films tend to deteriorate at high humidity.
One solution discussed in the prior art is to deposit a thin vacuum coating layer directly onto the MFC film or coating using for example chemical or physical vapor deposition techniques. The thin vacuum coating layer may for example comprise a thin layer of aluminum, AlzOs, AlOx, or SiOx. A problem with these deposition techniques is that the coating process takes place under vacuum, which means that the substrate needs to degassed. For MFC films and coatings, this means that the process adds costs, but the degassing also means that the substrate is dried to a very low moisture content. This drying and the subsequent remoisturizing to ambient moisture levels changes the mechanical properties of the MFC films and coatings. The drying will not only increase the cracking tendency and post- convertability of the MFC films and coatings but there is also a significant risk of cracking of the thin and sensitive vacuum coating layer as the film or coating is
remoisturized.
Thus, there remains a need for improved solutions to replace the combination of plastic films and aluminum foils in paper and paperboard based packaging materials, while maintaining acceptable liquid, water vapor, and oxygen barrier properties. At the same time, there is a need to replace the combination of plastic films and aluminum foils with alternatives that facilitate re-pulping and recycling of
the used packaging materials.
Description of the invention
lt is an object of the present disclosure to provide an alternative to the combination of plastic films and aluminum foils commonly used as barrier layers for providing water vapor barrier properties in packaging materials, such as liquid or food
packaging board.
lt is a further object of the present disclosure, to provide a barrier layer for a paper or paperboard based packaging laminate, such as a liquid or food packaging board, which provides good water vapor barrier properties even at higher relative
humidity and temperature.
lt is a further object of the present disclosure to provide a barrier layer, which has an oxygen transmission rate (OTR), measured according to the standard ASTM D- 3985 at 50% relative humidity and 23 °C, of less than 10 cc/m2/24h.
lt is a further object of the present disclosure to provide a barrier layer, which has a water vapor transmission rate (WVTR), measured according to the standard ASTM F1249 at 50% relative humidity and 23 °C, of less than 10 g/m2/24h.
lt is a further object of the present disclosure to provide a barrier layer for a paper or paperboard based packaging laminate, such as a liquid or food packaging board, which barrier layer facilitates re-pulping of the packaging laminate as compared to packaging laminates using conventional combinations of plastic films
and aluminum foils.
The above-mentioned objects, as well as other objects as will be realized by the skilled person in the light of the present disclosure, are achieved by the various
aspects of the present disclosure.
The present invention is based on the understanding that very thin coating layers, typically having a thickness in the range of 20-600 nm, and more preferably in the range of 50-250 nm, formed by vacuum deposition processes, such as physical
vapor deposition (PVD) or chemical vapor deposition (CVD), can when combined
with a substrate formed of highly refined cellulose pulp (HRC) or microfibrillatedcellulose (MFC) provide good oxygen and water vapor barrier properties, comparable to the barrier properties of thicker aluminum foils. As the thickness of the vacuum deposited coatings is typically at least an order of magnitude lower than the thickness of conventional foils, the metal content of the products can be
dramatically reduced.
However, vacuum deposition coating performed directly on the substrate to be coated, so called direct vacuum coating, or direct metallization, has been found to be problematic for substrates formed of highly refined cellulose pulp (HRC) or microfibrillated cellulose (MFC). More specifically, degassing in connection with the vacuum treatment means that the substrate is dried to a very low moisture content. This drying and the subsequent remoisturizing to ambient moisture levels changes the mechanical properties of the HRC or MFC substrates. The drying will not only increase the cracking tendency and post-convertability of the substrates, but there is also significant risk of cracking of the thin and sensitive vacuum coating layer as the substrate is remoisturized.
The present invention is based on the realization that these problems can be overcome by replacing direct vacuum deposition coating of the substrate with a transfer coating technique, thus avoiding vacuum treatment of the barrier substrate.
According to a first aspect illustrated herein, there is provided a method for manufacturing a barrier layer for a paper or paperboard based packaging laminate, said method comprising:
a) providing a barrier substrate comprising at least 50 wt% highly refined cellulose pulp (HRC) based on dry weight of the barrier substrate, said HRC having a Schopper-Riegler (SR) number above 80 as determined by standard ISO 5267-1,
b) providing a transfer coating substrate comprising a vacuum coating layer and a backing layer separated by a release layer, and
c) transferring the vacuum coating layer from the backing layer to the barrier
substrate by a transfer coating process using an adhesive layer applied on thebarrier substrate and/or the vacuum coating layer to obtain a barrier layer for a paper or paperboard based packaging laminate.
Transfer coating of vacuum coating layers, also commonly referred to as transfer
metallization when the coating comprises a metal, is a method conventionally used for preparing decorative layers on graphical paper substrates. The present inventors have found this coating technique, when combined with a substrate formed of highly refined cellulose pulp (HRC) or microfibrillated cellulose (MFC), can be used to form a highly useful oxygen and water vapor barrier layer suitable for paper or paperboard based packaging laminates. ln addition to providing good oxygen and water vapor barrier properties, the inventive barrier layer may also form a good barrier for other gases, as well as aromas and odors.
Thus, the barrier substrate used in the inventive method comprises highly refined cellulose pulp. Refining, or beating, of cellulose pulps refers to mechanical treatment and modification of the cellulose fibers in order to provide them with desired properties. The highly refined cellulose fibers can be produced from different raw materials, for example softvvood pulp or hardwood pulp. The highly
refined cellulose fibers are preferably never dried cellulose fibers.
The barrier substrate comprises at least 50 wt% highly refined cellulose pulp (HRC) based on dry weight of the barrier substrate. ln some embodiments, the barrier substrate comprises at least 70 wt%, preferably at least 90 wt%, highly refined cellulose pulp based on the dry weight of the barrier substrate.
The HRC has a Schopper-Riegler (SR) number above 80 as determined by standard ISO 5267-1. ln some embodiments, the highly refined cellulose pulp has a Schopper-Riegler (SR) number above 85, preferably above 90, as determined by standard ISO 5267-ln some embodiments, the highly refined cellulose pulp is a microfibrillated cellulose (MFC).
Microfibrillated cellulose (MFC) shall in the context of the patent application mean a cellulose particle, fiber or fibril having a width or diameter of from 20 nm toHm.
Various methods exist to make MFC, such as single or multiple pass refining, pre- hydrolysis followed by refining or high shear disintegration or liberation of fibrils. One or several pre-treatment steps is usually required in order to make MFC manufacturing both energy efficient and sustainable. The cellulose fibers of the pulp used when producing MFC may thus be native or pre-treated enzymatically or chemically, for example to reduce the quantity of hemicellulose or lignin. The cellulose fibers may be chemically modified before fibrillation, wherein the cellulose molecules contain functional groups other (or more) than found in the original cellulose. Such groups include, among others, carboxymethyl (CM), aldehyde and/or carboxyl groups (cellulose obtained by N-oxyl mediated oxidation, for example "TEMPO"), or quaternary ammonium (cationic cellulose). After being modified or oxidized in one of the above-described methods, it is easier to disintegrate the fibers into MFC.
MFC can be produced from wood cellulose fibers, both from hardwood or softwood fibers. lt can also be made from microbial sources, agricultural fibers such as wheat straw pulp, bamboo, bagasse, or other non-wood fiber sources. lt can be made from pulp, including pulp from virgin fiber, e.g. mechanical, chemical
and/or thermomechanical pulps. lt can also be made from broke or recycled paper.
The barrier substrate is preferably formed from an aqueous suspension of the highly refined cellulose pulp which is then formed into a sheet or web and dewatered and/or dried. Forming, dewatering and drying of the barrier substrate can be done using methods known in the art, including but not limited to, casting on a solid surface followed by drying, forming on a paper or paperboard substrate followed by dewatering and drying, and forming on wire of a paper machine
followed by dewatering and drying.
Depending on how the barrier substrate is prepared, the barrier substrate may be considered as a free-standing barrier substrate film or as a coating layer on a
paper or paperboard substrate.
ln some embodiments, the barrier substrate has a grammage in the range of 2- 100 g/m2, preferably in the range of 2-60 g/m2, and more preferably in the range of 20-50 g/m
ln some embodiments, the barrier substrate is a free-standing barrier substrate film. The term film as used herein refers generally to a thin continuous sheet formed material. Depending on the composition of the barrier substrate film, the film can also be considered as a thin paper or even as a membrane. A free- standing barrier substrate should preferably have sufficient thickness, mechanical strength and rigidity in order for it to be handled, e.g. reeled, unreeled, coated, and/or laminated to a paper or paperboard substrate. A barrier substrate in the form of a free-standing barrier substrate film may typically have a grammage in the range of 20-100 g/m2, preferably in the range of 20-60 g/m2, and more preferably in the range of 20-50 g/m
ln some embodiments, the barrier substrate is instead a coating layer on a paper or paperboard substrate. When the barrier substrate is formed, or coated, on a paper or paperboard substrate followed by dewatering and drying, the resulting barrier substrate may be seen as a coating layer on the paper or paperboard substrate. A barrier substrate in the form of a coating layer on a paper or paperboard substrate can be made significantly thinner than a free-standing barrier substrate film, since mechanical strength and rigidity for handling can be provided by the paper or paperboard substrate. A barrier substrate in the form of a coating layer on a paper or paperboard substrate may typically have a grammage in the range of 2-20 g/m2, preferably in the range of 2-15 g/m2, and more preferably in the range of 2-10 g/m
The barrier substrate is typically relatively dense. ln some embodiments, the
barrier substrate has a density above 800 kg/m3, preferably above 900 kg/mUnless otherwise stated, the density is determined according to the standard ISO
ln some embodiments, the barrier substrate has a Gurley Hill value above 5000 s/100ml, preferably above 20 000 s/100ml, and more preferably above 42 300 s/100ml, as measured according to standard ISO 5636-
The inventive method is especially advantageous for substrates which are difficult or costly to dry completely. As the method does not involve subjecting the barrier substrate itself to a vacuum coating process, a relatively high remaining moisture content in the barrier substrate when the transfer coating process is performed can be accepted. Thus, in some embodiments, the barrier substrate, when subjected to the transfer coating process, has a moisture content 1.5 wt% or more, preferably 2 wt% or more, more preferably 3 wt% or more or 3.5 wt% or more or 4 wt% or more. The moisture content of the barrier substrate is preferably 15 wt% or less, 12 wt% or less, 10 wt% or less, or 9 wt% or less. ln some embodiments the barrier substrate has a moisture content of 4 wt% or higher, such as in the range of 4-15 wt%, 4-12 wt%, 5-10 wt%, or 6-9 wt%. Unless otherwise stated, the moisture content is determined according to the standard ISO
The barrier substrate comprising at least 50 wt% highly refined cellulose pulp (HRC) based on dry weight of the barrier substrate will typically have a relatively low resistance to water vapor. ln some embodiments, the barrier substrate has a water vapor transmission rate (WVTR), measured according to the standard ASTM F1249 at 50% relative humidity and 23 °C, of above 30 g/m2/24h.
Onto the provided barrier substrate, a vacuum coating layer is applied by a transfer coating process to obtain a barrier layer for a paper or paperboard based packaging laminate. Transfer coating, also commonly referred to as transfer metallization when the coating comprises a metal, generally involves transferring a thin vacuum coating layer from a transfer coating substrate to a substrate to be coated, using an adhesive layer applied between the vacuum coating layer and the substrate to be coated.The transfer coating substrate comprises a vacuum coating layer and a backing layer, and the vacuum coating layer and the backing layer are separated by a release layer having low adhesion to the vacuum coating layer and/or the backing layer, such that the vacuum coating layer can be readily separated from the
backing layer.
For the transfer coating process, an adhesive layer is applied on the barrier substrate or on the vacuum coating layer or on both layers. The vacuum coating layer is transferred to the barrier substrate using the adhesive layer applied on the barrier substrate and/or the vacuum coating layer. The vacuum coating layer is contacted and adhered to the barrier substrate using the adhesive layer applied on the barrier substrate and/or the vacuum coating layer. Once the vacuum coating layer has adhered to the barrier substrate, the backing layer removed from the vacuum coating layer, leaving the adhered vacuum coating layer, and optionally the release layer, on the barrier substrate. Possible additional layers added between the release layer and the vacuum coating layer, and/or on top of the
vacuum coating layer will also remain on the barrier substrate.
ln some embodiments, the transfer coating process comprises
contacting and adhering the vacuum coating layer to the barrier substrate using the adhesive layer applied on the barrier substrate and/or the vacuum coating layer, and
removing the backing layer, leaving the vacuum coating layer, and optionally the release layer, on the barrier substrate.
The vacuum coating layer in contact with the barrier substrate via the adhesive layer may be subjected to various treatments for improving the adhesion between the vacuum coating layer and the barrier substrate. ln some embodiments, the vacuum coating layer in contact with the barrier substrate via the adhesive layer is subjected to pressure, heat, and/or radiation to improve adhesion between the vacuum coating layer and the barrier substrate.
The temperature may vary depending on contact time and pressure but should generally be in the range of 40-250 °C, and preferably in the range of 60-150 °C.
The pressure should be high enough to obtain good transfer of the vacuum coating layer. ln some embodiments, the pressure is in the range of 1-50 kg/cm. Pressure and heating may for example be provided in a heated nip or extended
nip.
Transfer coating substrates similar to those for use in the present invention are known in the art, e.g. for preparing decorative layers on graphical paper substrates. However, as the purpose of the inventive method is to provide a barrier layer, the composition morphology and thickness of the vacuum coating layer may differ from those used for decorative purposes. The transfer coating substrate is typically prepared by coating a backing layer, preferably a polymer film, with a release layer. A vacuum coating layer is then deposited on the release layer. Optionally, additional intermediate layers may be added between the release layer and the vacuum coating layer, and/or top layers may be added on top of the vacuum coating layer. Additional layers may include protective layers for protecting the sensitive vacuum coating layer before the coating layer has been separated from the backing layer (protective top layer on top of the vacuum coating layer), or after the vacuum coating layer has been separated from the backing layer (protective intermediate layer between the release layer and the vacuum coating layer). Additional intermediate or top layers may also include barrier layers, e.g. gas or moisture barrier layers, or primer layers for improving the adhesion of the vacuum coating layer.
The backing layer primarily serves as a carrier for the release layer and the vacuum coating layer. The backing layer should preferably provide suitable mechanical and strength properties for the transfer coating process and a smooth and pinhole free surface for formation of the release layer and the vacuum coating layers. ln some embodiments, the backing layer comprises a plastic film. The plastic film may for example be a polyethylene terephthalate (PET) film, but the skilled person understands that other polymer films may also be useful. After it has been removed from the vacuum coating layer during the transfer coating process, the backing layer may preferably be used again.Release layers for transfer coating applications are well known in the art. Release layers may have many different chemical compositions with the common feature of having relatively weak adhesion to a substrate, such that the release layer can be easily removed or stripped from the substrate. Examples of common materials for use in the release layer include, but are not limited to, a film forming vinyl chloride- vinyl acetate copolymer or a film forming vinylidene chloride copolymer, or a
combination thereof.
ln some embodiments, the release layer comprises a layer of a material having lower adhesion to the backing layer or to the vacuum coating layer than the adhesion of the adhesive layer to the barrier substrate and to the vacuum coating layer. ln this way, the vacuum coating, and possibly also the release layer, will
remain on the adhesive layer when the backing layer is removed.
When the backing layer is removed the release layer may, depending on the adhesion characteristics of the release layer, either remain on the backing layer or on the vacuum coating layer. For achieving consistent production and performance, it is of course preferred that the release layer is not retained partially on the backing layer and partially on the vacuum coating layer when the backing layer is removed. The release layer is preferably selected such that the adhesion to either the backing layer or the vacuum coating layer is significantly stronger than the other, such that the entire release layer remains on one of the two surfaces as the backing layer is removed. ln some embodiments, the release layer comprises a layer of a material having lower adhesion to the backing layer than to the vacuum coating layer, or having lower adhesion to the vacuum coating layer than to the backing layer, such that the entire release layer remains on the vacuum coating layer or on the backing layer when the backing layer is removed. lt is typically preferred that the release layer remains on the vacuum coating layer when the backing layer is removed since the backing layer can then be conveniently coated again and reused. Thus, in some embodiments, the release layer is selected such that the adhesion between the vacuum coating layer and the release layer is significantly stronger than the adhesion between the release layer and the backing layer, such that the entire release layer remains on the surface of
the vacuum coating layer as the backing layer is removed. The release layer onthe surface of the vacuum coating layer will then act as a protective coating or varnish on the vacuum coating layer. Furthermore, the backing layer from which both the vacuum coating layer and the release layer has been removed during the transfer coating process may conveniently be used again in the preparation of a new transfer coating substrate. When an intermediate polymer layer is applied between the release layer and the vacuum coating layer, the intermediate polymer layer will remain on the surface of the vacuum coating layer as the backing layer is removed, and the intermediate polymer layer on the surface of the vacuum coating layer will also act as a protective coating on the vacuum coating layer. As an example, a carrier film, e.g. a PET film, is provided with a release layer (0.05-5 gsm), a protective coating 0.5-15 gsm, on top of the release layer, and then the thin vacuum coating layer on top of the protective coating. ln some embodiments, the adhesive layer may also be provided on top of the vacuum coating layer. ln addition to acting as an adhesive when the vacuum coating layer is transferred to the paper or paperboard substrate, the adhesive layer may also act as a protective coating for the vacuum coating layer during transport and handling.
The vacuum coating layer is formed on the release layer, or on an additional polymer layer applied on top of the release layer. Vacuum coating refers to a family of processes used to deposit layers of metals, metal oxides and other inorganic and organic compositions, typically atom-by-atom or molecule-by- molecule, on a solid surface. Multiple layers of the same or different materials can be combined. The process can be further specified based on the vapor source; physical vapor deposition (PVD) uses a liquid or solid source and chemical vapor deposition (CVD) uses a chemical vapor.
Vacuum coating typically results in very thin coatings. ln some embodiments, the vacuum coating layer has a thickness in the range of 10-600 nm, preferably in the range of 10-250 nm, and more preferably in the range of 50-250 nm. This should be compared to conventional aluminum foils used in packaging laminates, which
foils typically have thickness in the range of about 3-12 um.vi. . .Å .V ._ ,. .\ .\. A: A 5.. ._ . ._ _.. f. .- i~ .s :..\ _.. .a ..\ : .-\ »W _. .N .s :N :m m. .M .»\ .~ m :m- rw. m» .w .\\.\\-\\-.\.\. .n \-'~<“\.\.«~. .\«\ ~\\«' \\-'. . .~\«*\' Xa ~' *i ~ -“\\-§\\«'\ ~!\»* «^~ \.~. Q\.\. 5- I- .\ \ \,\\\~. ..\\\ \\~'. ..\<^\\~ ß.. .. än ~\<\~~ \~\ .å J \~' \~°
àflšïflhe vacuum coating layer comprises an inorganic vacuum coating layer-vs
_, __\_ _.. \.~_.\ v.. ;'_.\ \ _ _.\ N, _ ¿ vw.. N ,,\ _.\ Q. I .N N l ,.\ . . M W .J .'\ \.\...\\»' \.\ I d .. '\ \
un. .en .-». G .~
One preferred type of vacuum coating, often used for its barrier properties, in
particular water vapour barrier properties, is an aluminum metal physical vapour deposition (PVD) coating. Such a coating, substantially consisting of aluminum metal, may typically have a thickness of from 50 to 250 nm, although a thickness even lower than 50 nm may also be useful, and even preferred in some embodiments. The thickness of the vacuum coating layer corresponds to less than 1 % of the aluminum metal material typically present in an aluminum foil of conventional thickness for packaging, i.e. 6.3 um. Thus, in some embodiments,
the vacuum coating layer comprises aluminum.
The thickness of the vacuum coating layer may also be characterized by the optical density of the layer. ln some embodiments the vacuum coating layer has an optical density above 1.8, preferably above 2.0, above 2.5, above 2.7, or above 3.
Aluminum oxide vacuum coating layers also known as AlOx coatings can provide similar barrier properties as aluminum metal coatings, but have the added advantage of thin AlOx coatings being transparent to visible light.The transfer coating substrate may further comprise a protective layer applied on top of the vacuum coating layer for protecting the thin and sensitive vacuum coating layer during manufacture, handling and transport prior to the transfer coating process. The protective layer applied on top of the vacuum coating layer may remain of the vacuum coating layer during the transfer coating process and form part of the obtained barrier layer. Alternatively, in some embodiments the protective layer applied on top of the vacuum coating layer may be removed before the transfer coating process.
During the transfer coating process, the vacuum coating layer is transferred from the backing layer to the barrier substrate using an adhesive layer applied on the barrier substrate and/or the vacuum coating layer to obtain a barrier layer for a paper or paperboard based packaging laminate. Many different types of adhesives and adhesive coating methods may be used with the invention.
Typically, the adhesive layer will comprise one or more adhesive polymers. The adhesive layer may be comprised entirely of the one or more adhesive polymers, or it may also further comprise other additives for facilitating the coating process or improving the properties of the adhesive layer.
ln some embodiments, the adhesive layer comprises at least 50 wt% of an
adhesive polymer or mixture of adhesive polymers based on dry weight.
ln some embodiments, the adhesive layer comprises at least 50 wt% of a water- soluble polymer or mixture of water-soluble polymers based on dry weight. The water-soluble polymer of the adhesive layer is soluble in cold water or soluble in hot water, e.g. at a temperature below 100 °C or even above 100 °C, for a given period of time. The water-soluble polymer in addition to acting as an adhesive for the vacuum coating layer, also facilitates separation of the vacuum coating layer
and optional additional plastic layers applied on top of the adhesive layer or
vacuum coating layer during repulping. fr: ;:f:::>~:::,.. ::::“;:&1.:~;~'>ïï:>:'::,.:':ï::, få:
The adhesive layer may be applied by any suitable method known in the art. The adhesive layer may for example be applied as a solution or dispersion in an aqueous or organic solvent carrier using liquid coating methods known in the art,
in melt form using extrusion coating, or in the form of a solid film by lamination.
The adhesive layer may be applied directly to the barrier substrate surface, or it may first be applied to the vacuum coating layer, and then applied to the barrier substrate together with the vacuum coating layer, or both. An advantage of applying the adhesive coating to both surfaces is that the wetting of the surfaces is reduced.
To minimize the risk of pinholes in the adhesive layer, the adhesive layer may preferably be applied in at least two different coating steps with drying of the coated film between the steps.
The adhesive layer is preferably formed by means of a liquid film coating process, i.e. in the form of a solution or dispersion which, on application, is spread out to a thin, uniform layer on the substrate and thereafter dried. The liquid phase of the solution or dispersion is preferably water or an aqueous solution, but organic solvents or mixtures of water or aqueous solutions and organic solvents may also be used. The one or more adhesive polymers may be present in the solution or dispersion in dissolved form or in the form of polymer particles, such as a latex. The adhesive layer can be applied by contact or non-contact coating methods. Examples of useful coating methods include, but are not limited to rod coating, curtain coating, film press coating, cast coating, transfer coating, size press coating, flexographic coating, gate roll coating, twin roll HSM coating, blade coating, such as short dwell time blade coating, jet applicator coating, spray
coating, gravure coating or reverse gravure coating.ln some embodiments, at least one adhesive layer is applied in the form of a foam. Foam coating is advantageous as it allows for film forming at higher solids content and lower water content compared to a non-foamed coating. The lower water content of a foam coating also reduces the problems with rewetting of the barrier substrate. The foam may be formed using a polymeric or non-polymeric foaming agent. Examples of polymeric foaming agents include PVOH, hydrophobically modified starch, and hydrophobically modified ethyl hydroxyethyl cellulose.
\ i \ n M .\_. _. . _ .t ,.\ . t, .c _., _., _.\ _. fr>vsåwxš:»:~fzïš»~ëtx\-f~fx*z * .~:=\.*§:~§>~.-~\.L.-\.v\}= \
the adhesive layer
further comprises a crosslinking agent ' *§§__capable of
crosslinking the water-soluble The crosslinking agent may advantageously be applied together with the water-soluble polymer, and then activated, e.g. by heat or radiation, when the adhesive layer is in contact with the vacuum coating layer. Crosslinking improves the water vapor barrier properties of the adhesive layer. Suitable crosslinking agents include, but are not limited to
polyfunctional organic acidstss
such as citric acidsfigš. __
ln some embodiments, the crosslinking agent is
\. \.
“ fås-citric acid. The concentration of the crosslinking agent may for example be 1-20 wt%, preferably 1-15 wt%, based on the dry weight of the
adhesive layer.
ln some embodiments, the adhesive layer comprises PVOH and citric acid. Crosslinking of the PVOH with citric acid improves the water vapor barrier properties of the adhesive layer. Additionally, the crosslinking of the PVOH with citric acid in contact with the vacuum coating layer has been found to further improve adhesion of the vacuum coating layer and the overall water vapor barrier
properties of the barrier layer.
ln some embodiments, the adhesive layer comprises one or more additional polymer(s) in a total amount of 0-50 wt% based on dry weight. The additional polymer(s) may act to crosslink and/or further improve adhesion to the vacuum coating layer. Suitable additional polymer(s) include, but are not limited to polyvinyl
pyrrolidone, polyvinyl amide, polyvinyl ethylene imine, polyacrylamide, cationicpolyacrylamide, polyurethane, and derivatives thereof. Other suitable additional po|ymer(s) include latexes, such as styrene acrylate latex (SA latex), styrene butadiene latex (SB latex), polyvinyl acetate (PVAc), styrene butadiene acrylonitrile (SBN), polyvinylidene dichloride (PVDC), and hybrid-polymer
emulsions such as grafted starch.
The basis weight of the adhesive layer may generally be in the range of 1-20 g/m
ln some embodiments, the grammage of the adhesive layer is in the range of 2-g/m2, more preferably in the range of 3-12 g/m
ln some embodiments, the adhesive layer further comprises up to 50 wt% of microfibrillated cellulose (MFC), nanocrystalline cellulose, a chemically modified cellulose derivative such as sodium carboxymethyl cellulose, hydroxypropyl cellulose, ethyl hydroxyethyl cellulose, cellulose acetate, hydroxyethyl cellulose, a hemicellulose, or a combination thereof, based on dry weight.
ln some embodiments, the obtained barrier layer has an oxygen transmission rate (OTR), measured according to the standard ASTM D-3985 at 50% relative humidity and 23 °C, of less than 10 cc/m2/24h, preferably less than 5 cc/m2/24h, and more preferably less than 1 cc/m2/24h.
ln some embodiments, the obtained barrier layer has a water vapor transmission rate (WVTR), measured according to the standard ASTM F1249 at 50% relative humidity and 23 °C, of less than 10 g/m2/24h, preferably less than 5 g/m2/24h, and more preferably less than 1 g/m2/24h.
ln addition to providing good oxygen and water vapor barrier properties, the inventive barrier layer may also form a good barrier for other gases, as well as
aromas and odors.
According to a second aspect illustrated herein, there is provided a method for manufacturing a paper or paperboard based packaging laminate, said method comprising:
i) providing a paper or paperboard substrate, andii) providing a barrier layer manufactured according to the method according to the first aspect on the paper or paperboard substrate to obtain the paper or paperboard based packaging laminate.
Paper generally refers to a material manufactured in thin sheets from the pulp of wood or other fibrous substances comprising cellulose fibers, used for writing,
drawing, or printing on, or as packaging material.
Paperboard generally refers to strong, thick paper or cardboard comprising cellulose fibers used for boxes and other types of packaging. Paperboard can either be bleached or unbleached, coated or uncoated, and produced in a variety of thicknesses, depending on the end use requirements. Paperboard may be a single ply material, or a multiply material comprised of two or more plies. A common type of multiply paperboard is comprised of a lower density mid-ply (also sometimes referred to as “bulk ply”) sandwiched between two higher density outer plies. The lower density mid-ply may typically have a density below 750 kg/m3, preferably below 700, below 650, below 600, below 550, below 500, below 450, below 400 or below 350 kg/m3. The higher density outer plies typically have a density at least 100 kg/m3 higher than the mid-ply, preferably at least 200 kg/m3 higher than the mid-ply.
A paper or paperboard based packaging laminate is a packaging material formed mainly from paperboard. The paper or paperboard substrate can be made from pulp, including pulp from virgin fiber, e.g. mechanical, chemical and/or thermomechanical pulps. lt can also be made from broke or recycled paper. ln addition to the paper or paperboard, the paper or paperboard based packaging laminate may comprise additional layers or coatings designed to improve the performance and/or appearance of the packaging laminate.
The paper or paperboard based packaging laminate typically has a first outermost surface intended to serve as the outside surface, or print side, and a second outermost surface intended to serve as the inside surface of a packaging container. The side of the paper or paperboard substrate comprising the inventivebarrier layer is preferably intended to serve as the inside surface of a packaging
container.
ln some embodiments, the paper or paperboard substrate has a grammage of at least 100 g/m2. ln some embodiments, the paper or paperboard substrate has a grammage of at least 150 g/m2, 200 g/m2, 250 g/m2, 300 g/m2, 350 g/m2, or 400 g/m2. The grammage of the paper or paperboard substrate is preferably below 1000 g/m2, 800 g/m2, or 600 g/m2. Unless othen/vise stated, the grammage is determined according to the standard ISO
ln some embodiments, the paper or paperboard substrate has a density below 700 kg/m3, preferably below 600 kg/m3. Unless otherwise stated, the density is determined according to the standard ISO
The paper or paperboard substrate may be a single ply paperboard or a multiply paperboard. ln some embodiments, the paper or paperboard substrate is a multiply paperboard. ln some embodiments the paper or paperboard substrate is a multiply paperboard comprised of two or more plies. ln some embodiments the paper or paperboard substrate is a multiply paperboard comprised of three or more plies. ln some embodiments the paper or paperboard substrate is a multiply paperboard comprised of a lower density mid-ply sandwiched between two higher
density outer plies.
ln some embodiments, the paper or paperboard substrate is a foam formed paperboard. ln some embodiments wherein the paper or paperboard substrate is a
multiply paperboard, at least one of the plies, preferably a mid-ply, is foam formed.
The structure of the inventive paper or paperboard based packaging laminate enables the use of a larger amount of recycled fibers in the paper or paperboard substrate since the barrier structure hinders the migration of mineral oil based compounds. Thus, in some embodiments, the paper or paperboard substrate comprises at least 5 wt% recycled fibers, preferably at least 10 wt% recycled fibers.
ln some embodiments, the paper or paperboard substrate further comprises a mineral coating layer on one or both of its main surfaces. ln some embodiments, the mineral coating layer comprises
50-95 wt% of a particulate mineral, and 5-50 wt% of a binder,
based on the total dry weight of the mineral coating layer.
ln some embodiments, the mineral coating layer comprises 10-35 wt% binder.
ln some embodiments, the particulate mineral is selected from the group consisting of kaolin, calcium carbonate, bentonite, talc, and combinations thereof, preferably kaolin or calcium carbonate, and more preferably kaolin.
The binder may comprise a single binder or a combination of binders. The binder may preferably comprise a water-dispersible or water-soluble binder, or a combination thereof. ln some embodiments, the water-dispersible binder comprises a latex binder. ln some embodiments, the water-soluble binder comprises a starch, PVOH, a cellulose derivate such as CMC, a protein, or seaweed. An advantage of using a water-soluble binder is that the laminate will be
even more easy to recycle.
ln some embodiments, the grammage of the mineral coating layer is in the range of 4-30 g/m2, more preferably in the range of 6-14 g/m
The mineral coating layer may preferably be applied in at least two different coating steps with drying of the coated film between the steps. The mineral coating layer may also be calendered, preferably in a soft calender or belt calender.
The provision of the inventive barrier layer on the paper or paperboard substrate can be achieved in a number ofdifferent ways.ln some embodiments, the provision in step ii) comprises laminating a free- standing barrier layer manufactured according to the first aspect to the paper or paperboard substrate.
ln some embodiments, the provision in step ii) comprises laminating a barrier substrate comprising at least 50 wt% highly refined cellulose pulp (HRC) based on dry weight of the barrier substrate to the paper or paperboard substrate and then transferring the vacuum coating layer from the backing layer of the transfer coating
substrate to the barrier substrate according to the first aspect.
Lamination of the barrier layer or barrier substrate to the paper or paperboard substrate can be achieved using an adhesive tie layer applied between the barrier layer or barrier substrate and the paper or paperboard substrate. The tie layer may be an adhesive layer applied by any suitable method known in the art. The tie layer may for example be an adhesive layer applied as a solution or dispersion of an adhesive in an aqueous or organic solvent carrier using liquid coating methods known in the art, or an adhesive applied in melt form using extrusion coating, or in the form ofa solid adhesive film by lamination.
ln some embodiments, the provision in step ii) comprises coating the paper or paperboard substrate with a coating dispersion comprising at least 50 wt% highly refined cellulose pulp (HRC) based on dry weight of the coating dispersion and drying the coating dispersion to form a barrier substrate on the paper or paperboard substrate, and then transferring the vacuum coating layer from the backing layer to the barrier substrate according to the first aspect.
fl~ --a barrier layer obtained by a method according to the first aspect.
, q M y. _ m. ,\\ v, . . ¿.~~-;.\ _. - N ..\ . Mwx ä ;.\ (_: _.\ yçnw ,\ -N § _.\» ge N» ,.\¿\ . . \.~_.\ på _ .\ _.\ _.\\ ,\ O ,.\_.\_ ~\\ __: _.\ š . _ i _ N, “N s _.\ _. . _ ..\.. . y t., c _\.- .- t i : =\.- u: ve *vi h \.~ m “väx-xx kl: L» = tm» \.~ x.. .o \.-: us-x-š: :frušäwxfwsbzxïrxš
š“.";:“;:ï:^.. ïfrfaf-t 5:: ;f:;:**: a paper or paperboard based packaging laminate obtained by a method according to the second aspect.The inventive paper or paperboard based packaging laminate can provide an alternative to conventional materials using aluminum foil layers, which can more readily be repulped and recycled. ln some embodiments, the paper or paperboard based packaging laminate has a reject rate according to PTS RH 021/97 of less than 30 %, preferably less than 20 %, more preferably less than 10%.
The paper or paperboard based packaging laminate may further be provided with an outermost polymer layer on one side or on both sides. The outermost polymer layers preferably provide liquid barrier properties and mechanical protection for the paper or paperboard based packaging laminate surface. The outermost polymer layer is preferably also heat-sealable.
ln some embodiments, the paper or paperboard based packaging laminate comprises a first outermost polymer layer, preferably a polyethylene layer, arranged on the paper or paperboard substrate.
ln some embodiments, the paper or paperboard based packaging laminate further comprises a second outermost polymer layer, preferably a polyethylene layer,
arranged on the vacuum coating layer.
The outermost polymer layers may of course interfere with repulpability but may still be required or desired in some applications. The additional polymer layers may for example be applied by extrusion coating, film lamination or dispersion coaüng.
The outermost polymer layers may comprise any of the thermoplastic polymers commonly used in protective and/or heat-sealable layers in paper or paperboard based packaging laminates in general or polymers used in liquid or food packaging board in particular. Examples include polyethylene (PE), polyethylene terephthalate (PET), polyethylene furanoate (PEF), polypropylene (PP), polyhydroxyalkanoates (PHA), polylactic acid (PLA), polyglycolic acid (PGA), starch and cellulose. Polyethylenes, especially low density polyethylene (LDPE) and high density polyethylene (HDPE), are the most common and versatilepolymers used in liquid or food packaging board. The polymers used are preferably manufactured from renewable materials.
Thermoplastic polymers, are useful since they can be conveniently processed by extrusion coating techniques to form very thin and homogenous films with good liquid barrier properties. ln some embodiments, the additional polymer layer comprises polypropylene or polyethylene. ln preferred embodiments, the outermost polymer layers comprise polyethylene, more preferably LDPE or HDPE.
ln some embodiments, the outermost polymer layers are formed by extrusion coating of the polymer onto a surface of the paper or paperboard substrate or laminate. Extrusion coating is a process by which a molten plastic material is applied to a substrate to form a very thin, smooth and uniform layer. The coating can be formed by the extruded plastic itself, or the molten plastic can be used as an adhesive to laminate a solid plastic film onto the substrate. Common plastic resins used in extrusion coating include polyethylene (PE), polypropylene (PP),
and polyethylene terephthalate (PET).
The basis weight of each of the outermost polymer layers is preferably less than 50 g/m2. ln order to achieve a continuous and substantially defect free film, a basis weight of the outermost polymer layer of at least 8 g/m2, preferably at least 12 g/m2 is typically required. ln some embodiments, the basis weight of the outermost polymer layer is in the range of 8-50 g/m2, preferably in the range of 12-50 g/m
Some examples of possible arrangements of the inventive barrier layer in a paper
or paperboard based packaging laminate are shown below:
- polyolefin/paperboard substrate/tie layer/barrier layer/polyolefin
- paperboard substrate/tie layer/adhesive layer/barrier layer/polyolefin
- polyolefin/paperboard substrate/mineral coating/tie layer/barrier
layer/polyolefin - paperboard substrate/tie layer/barrier layer/polyolefin - paperboard substrate/tie layer/barrier layer/primer coating layer/polyolefin
- ink receiving layer/paperboard/tie layer/barrier layer/polyolefinGenerally, while the products, polymers, materials, layers and processes are described in terms of “comprising” various components or steps, the products, polymers, materials, layers and processes can also “consist essentially of' or
“consist of' the various components and steps.
While the invention has been described with reference to various exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. ln addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
EXAMPLES
Example 1 (Comparative) - Direct vacuum coatinq of packaqinq paper
A one side mineral coated packaging paper substrate with a grammage of 80 g/m2 was used. The physical properties of the paper substrate were: grammage (ISO 536) 80 g/m2, thickness (ISO 534) 80 um, tensile strength (ISO 1924-2 (MD)) 4.3 kN/m, tearing strength (ISO 1974 (CD)) 650 mN, moisture content (ISO 638) 4.0 %, Cobb60 (ISO 535, reverse) 25 g/m2, and opacity (ISO 2471 (C/2°) 96%.
The barrier properties (OTR measured according to the standard ASTM D-3985 at 50% relative humidity and 23 °C and WVTR measured according to the standard ASTM F1249 at 50% relative humidity and 23 °C) of the paper substrate before vacuum coating were out of range (no barrier properties). The paper substrate was prime coated with a PVOH based solution in three thin layers to give a total coat weight of 4 g/m2. After coating, the paper substrate was subjected to vacuum coating with AlzOe, to obtain a coat weight corresponding to an optical density of 3.5. After the vacuum coating, the barrier properties (OTR and WVTR) were
measured again. The OTR (23/50) was 512 cc/m2/24 h and the WVTR (23/50) was 0.19 g/m2/24 h.
Example 2 - Transfer coatinq on packaqinq paper substrate
ln this case, a one side mineral coated packaging paper substrate having a grammage of 90 g/m2 was used and transfer coating was performed on the mineral coated side. The physical properties of the packaging paper substrate were: thickness (ISO 534): 90 um, tensile strength (ISO 1924-2 (MD)) 4.6 kN/m, tearing strength (ISO 1974 (CD)) 780 mN, moisture content (ISO 638) 4.0 %, Cobb60 (ISO 535, reverse) 25 g/m2, and opacity (ISO 2471 (C/2°) 97%.
For the transfer coating, a transfer coating substrate vas prepared by vacuum depositing a layer of AlOx onto a release layer coated on a PET film backing layer. A water based polyurethane adhesive was applied onto the vacuum deposited layer and dried. The adhesive-AlOx layer was then transferred to the surface of the paper substrate using dry lamination under elevated temperature and pressure.
The backing layer was stripped off 24 h after the lamination.
The WVTR (ASTM F1249, 23/50) of the packaging paper substrate before transfer coating was out of range (no WVTR barrier). After transfer coating the WVTR (ASTM F1249, 23/50) was 0.3 g/m2/24 h.
Example 3 - Transfer coatinq on barrier substrate comprisinq hiqhlv refined pulp A highly refined pulp comprising 100% of pulp having a Schopper-Riegler value of about 95 as determined by standard ISO 5267-1was prepared into a thin 32 g/mbarrier substrate on a pilot paper machine.
The barrier substrate was then subjected to transfer coating as described in
Example
After the transfer coating, the barrier properties (OTR and WVTR) were measured. The OTR (ASTM D-3985, 23/50) was 2.5 cc/m2/24 h and the WVTR (ASTM F1249, 23/50) was 1.7 g/m2/24 h, confirming that both low OTR and WVTR can be
obtained after transfer coating of a barrier substrate comprising highly refined pulp.Example 4 - Transfer coatinq on PVOH coated barrier substrate comprisinq hiqhlv refined pulp
A highly refined pulp comprising about 80% of pulp with SR about 95 as determined by standard ISO 5267-1 and 20% of kraft pulp was prepared into a thin 32 g/m2 barrier substrate on a pilot paper machine. The OTR (ASTM D-3985, 23/50) of the uncoated substrate was > 366 cc/m2/24h and the WVTR (ASTM F1249, 23/50) was > 38 g/m2/24h.
The barrier substrate was prime coated with a PVOH based solution to give a total
coat weight of ca 2-4 g/m
The barrier substrate was then subjected to transfer coating as described in
Example
After the transfer coating, the barrier properties (OTR and WVTR) were measured. The OTR (ASTM D-3985, 23/50) was 0.3 cc/m2/24 h and the WVTR (ASTM F1249, 23/50) was 0.6 g/m2/24 h, confirming that both low OTR and WVTR can be
obtained after transfer coating of a barrier substrate comprising highly refined pulp.
Example 5 - Transfer metallization on barrier substrate comprisinq fine MFC
A fine MFC suspension was prepared by fibrillating enzyme treated kraft pulp and the MFC suspension was then cast formed into a barrier substrate having a grammage of 30 g/m2. The OTR (ASTM D-3985, 23/50) of the uncoated barrier substrate was 4.5 cc/m2/24 h and the WVTR (ASTM F1249, 23/50) was 46 g/m2/24 h.
The barrier substrate was then subjected to transfer coating as described in
Example
After the transfer coating, the barrier properties (OTR and WVTR) were measured. The OTR (ASTM D-3985, 23/50) was 0.4 cc/m2/24 h and the WVTR (ASTM F1249, 23/50) was 0.4 g/m2/24 h, confirming that both low OTR and WVTR can be
obtained after transfer coating of a barrier substrate comprising fine MFC.
Claims (26)
1. A method for manufacturing a barrier layer for a paper or paperboard based packaging laminate, said method comprising: a) providing a barrier substrate comprising at least 50 wt% highly refined cellulose pulp (HRC) based on dry weight of the barrier substrate, said HRC having a Schopper-Riegler (SR) number above 80 as determined by standard ISO b) providing a transfer coating substrate comprising a vacuum coating layer and a backing layer separated by a release layer, and c) transferring the vacuum coating layer from the backing layer to the barrier substrate by a transfer coating process using an adhesive layer applied on the barrier substrate and/or the vacuum coating layer to obtain a barrier layer for a paper or paperboard based packaging Iaminate, wherein the vacuum coating layer comprises an aluminum or aluminum oxide vacuum coating layer, and the adhesive layer comprises a water-soluble polyvinyl alcohol (PVOH) and an organic acid capable of crosslinking the PVOH.
2. The method according to claim 1, wherein the barrier substrate is a free- standing barrier substrate film.
3. The method according to claim 1, wherein the barrier substrate is a coating layer on a paper or paperboard substrate.
4. The method according to any one of the preceding claims, wherein the barrier substrate has a grammage in the range of 2-100 g/m2, preferably in the range of 2- 60 g/m2, and more preferably in the range of 20-50 g/m
5. The method according to any one of the preceding claims, wherein the barrier substrate comprises at least 70 wt%, preferably at least 90 wt%, highly refined cellulose pulp based on the dry weight of the barrier substrate.
6. The method according to any one of the preceding claims, wherein the highly refined cellulose pulp has a Schopper-Riegler (SR) number above 85, preferably above 90, as determined by standard ISO 5267-
7. The method according to any one of the preceding claims, wherein the highly refined cellulose pulp is a microfibrillated cellulose (MFC).
8. The method according to any one of the preceding claims, wherein the barrier substrate has a Gurley Hill value above 5000 s/100ml, preferably above 20 000 s/100ml, and more preferably above 42 300 s/100ml, as measured according to standard ISO 5636-
9. The method according to any one of the preceding claims, wherein the barrier substrate has a moisture content of 1.5 wt% or more, preferably 2 wt% or more, more preferably 3 wt% or more or 3.5 wt% or more or 4 wt% or more, as determined according to ISO
10. The method according to any one of the preceding claims, wherein the barrier substrate has a water vapor transmission rate (WVTR), measured according to the standard ASTM F1249 at 50% relative humidity and 23 °C, of above 30 g/m2/24h.
11. The method according to any one of the preceding claims, wherein the transfer coating process comprises contacting and adhering the vacuum coating layer to the barrier substrate using the adhesive layer applied on the barrier substrate and/or the vacuum coating layer, and removing the backing layer, leaving the vacuum coating layer, and optionally the release layer, on the barrier substrate.
12. The method according to any one of the preceding claims, wherein the vacuum coating layer in contact with the barrier substrate via the adhesive layer is subjected to pressure, heat, and/or radiation to improve adhesion between the vacuum coating layer and the barrier substrate.
13. The method according to any one of the preceding claims, wherein the backing layer comprises a plastic film.
14. The method according to any one of the preceding claims, wherein the release layer comprises a layer of a material having lower adhesion to the backing layer or to the vacuum coating layer than the adhesion of the adhesive layer to the barrier substrate and to the vacuum coating layer.
15. The method according to any one of the preceding claims, wherein the release layer comprises a layer of a material having lower adhesion to the backing layer than to the vacuum coating layer, or having lower adhesion to the vacuum coating layer than to the backing layer, such that the entire release layer remains on the vacuum coating layer or on the backing layer when the backing layer is removed _
16. The method according to any one of the preceding claims, wherein the vacuum coating layer has a thickness in the range of 10-600 nm, preferably in the range of 10-250 nm, and more preferably in the range of 50-250 nm.
17. The method according to any one of the preceding claims, wherein the adhesive layer comprises at least 50 wt% of an adhesive polymer or mixture of adhesive polymers based on dry weight.
18. The method according to any one of the preceding claims, wherein the adhesive layer comprises at least 50 wt% of a water-soluble polymer or mixture of water-soluble polymers based on dry weight.
19. The method according to any one of the preceding claims, wherein the organic acid is citric acid.
20. The method according to any one of the preceding claims wherein the adhesive layer further comprises up to 50 wt% of microfibrillated cellulose (MFC), nanocrystalline cellulose, a chemically modified cellulose derivative such as sodium carboxymethyl cellulose, hydroxypropyl cellulose, ethyl hydroxyethyl cellulose, cellulose acetate, hydroxyethyl cellulose, a hemicellulose, or a combination thereof, based on dry weight.
21. The method according to any one of the preceding claims, wherein the obtained barrier layer has an oxygen transmission rate (OTR), measured according to the standard ASTM D-3985 at 50% relative humidity and 23 °C, of less than 10 cc/m2/24h, preferably less than 5 cc/m2/24h, and more preferably less than 1 cc/m2/24h.
22. The method according to any one of the preceding claims, wherein the obtained barrier layer has a water vapor transmission rate (WVTR), measured according to the standard ASTM F1249 at 50% relative humidity and 23 °C, of less than 10 g/m2/24h, preferably less than 5 g/m2/24h, and more preferably less than 1 g/m2/24h.
23. A method for manufacturing a paper or paperboard based packaging laminate, said method comprising: i) providing a paper or paperboard substrate, and ii) providing a barrier layer manufactured according to the method defined in any one of claims 1-22 on the paper or paperboard substrate to obtain the paper or paperboard based packaging laminate.
24. The method according to claim 23, wherein step ii) comprises laminating a free-standing barrier layer manufactured according to the method defined in any one of claims 1-22 to the paper or paperboard substrate.
25. The method according to claim 23, wherein step ii) comprises laminating a barrier substrate comprising at least 50 wt% highly refined cellulose pulp (HRC) based on dry weight of the barrier substrate to the paper or paperboard substrate and then transferring the vacuum coating layer from the backing layer to the barrier substrate as defined in any one of claims 1-
26. The method according to claim 23, wherein step ii) comprises coating the paper or paperboard substrate with a coating dispersion comprising at least 50 wt% highly refined cellulose pulp (HRC) based on dry weight of the coating dispersion and drying the coating dispersion to form a barrier substrate on the paper or paperboard substrate, and then transferring the vacuum coating layer from the backing layer to the barrier substrate as defined in any one of claims 1- 22.
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
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SE2250283A SE545698C2 (en) | 2022-03-02 | 2022-03-02 | A method for manufacturing a barrier layer for a paper or paperboard based packaging laminate |
PCT/IB2023/051663 WO2023166387A1 (en) | 2022-03-02 | 2023-02-23 | A method for manufacturing a barrier layer for a paper or paperboard based packaging laminate |
Applications Claiming Priority (1)
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SE2250283A SE545698C2 (en) | 2022-03-02 | 2022-03-02 | A method for manufacturing a barrier layer for a paper or paperboard based packaging laminate |
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SE2250283A1 SE2250283A1 (en) | 2023-09-03 |
SE545698C2 true SE545698C2 (en) | 2023-12-12 |
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Citations (7)
Publication number | Priority date | Publication date | Assignee | Title |
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US4250209A (en) * | 1978-05-10 | 1981-02-10 | Lurex B.V. | Transfer metallizing process and product produced thereby |
US4473422A (en) * | 1981-03-11 | 1984-09-25 | Transfer Print Foils, Inc. | Metalized paper or board product and method of preparation |
WO2011141692A1 (en) * | 2010-05-10 | 2011-11-17 | Unilever Plc | Freeness of paper products |
EP3040198A1 (en) * | 2014-12-30 | 2016-07-06 | Toray Plastics (America) , Inc. | Releasable polyester high gloss metal transfer film |
WO2020169661A1 (en) * | 2019-02-20 | 2020-08-27 | Borregaard As | Production of corrugated paperboards and cardboards comprising chemically treated paper |
WO2020229675A1 (en) * | 2019-05-15 | 2020-11-19 | Knowfort Holding B.V. | Process for making multilayer structure with barrier properties |
GB2597553A (en) * | 2020-12-10 | 2022-02-02 | Damarell Keith | Laminated Packaging Material |
-
2022
- 2022-03-02 SE SE2250283A patent/SE545698C2/en unknown
-
2023
- 2023-02-23 WO PCT/IB2023/051663 patent/WO2023166387A1/en unknown
Patent Citations (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4250209A (en) * | 1978-05-10 | 1981-02-10 | Lurex B.V. | Transfer metallizing process and product produced thereby |
US4473422A (en) * | 1981-03-11 | 1984-09-25 | Transfer Print Foils, Inc. | Metalized paper or board product and method of preparation |
WO2011141692A1 (en) * | 2010-05-10 | 2011-11-17 | Unilever Plc | Freeness of paper products |
EP3040198A1 (en) * | 2014-12-30 | 2016-07-06 | Toray Plastics (America) , Inc. | Releasable polyester high gloss metal transfer film |
WO2020169661A1 (en) * | 2019-02-20 | 2020-08-27 | Borregaard As | Production of corrugated paperboards and cardboards comprising chemically treated paper |
WO2020229675A1 (en) * | 2019-05-15 | 2020-11-19 | Knowfort Holding B.V. | Process for making multilayer structure with barrier properties |
GB2597553A (en) * | 2020-12-10 | 2022-02-02 | Damarell Keith | Laminated Packaging Material |
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SE2250283A1 (en) | 2023-09-03 |
WO2023166387A1 (en) | 2023-09-07 |
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